One-dimensional continuous molded element

ABSTRACT

A molded fibrous structure comprising a continuous molded element. The continuous molded element may be one-dimensional. A method for making a molded fibrous structure comprising a continuous molded element. A substrate for use as a wipe made from a molded fibrous structure.

CROSS REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. application Ser. No.11/398,958, filed on Apr. 6, 2006, now U.S. Pat. No. 7,771,648 which ishereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

A process for preparing a one-dimensional, continuous, molded nonwovenfibrous structure and substrates made therefrom are provided.One-dimensional, continuous, molded nonwoven fibrous structures preparedby the inventive process and apparatus are also provided.

BACKGROUND OF THE INVENTION

Historically, various types of nonwoven fibrous structures have beenutilized as disposable substrates. The various types of nonwovens usedmay differ in visual and tactile properties, usually due to theparticular production processes used in their manufacture. In all cases,however, consumers of disposable substrates suitable for use as wipes,such as baby wipes, demand strength, thickness, flexibility, texture andsoftness in addition to other functional attributes such as cleaningability. Strength, thickness and flexibility can be correlated tocertain measurable physical parameters, but perceived softness andtexture are often more subjective in nature, and consumers often reactto visual and tactile properties in their assessment of wipes.Optimizing all the desirable properties is often not possible.

For example, often a balance of properties results in less thandesirable softness or strength levels. Wipes used as baby wipes, forexample, should be strong enough when wet to maintain integrity in use,but soft enough to give a pleasing and comfortable tactile sensation tothe user(s). They should have fluid retention properties such that theyremain wet during storage, and sufficient thickness, porosity, andtexture to be effective in cleaning the soiled skin of a user. Inaddition, sufficient thickness and texture should be retained when wet.

Strength in a nonwoven fibrous structure can be generated by a varietyof known methods. If thermoplastic fibers are used, strength can beimparted by melting, either by through-air bonding or by hot rollcalendaring. Adhesive bonding is also commonly used to bind fibers toincrease the strength of the nonwoven. However, these processes, whileincreasing the strength of the nonwoven, generally detract from otherdesirable properties, such as softness and flexibility. Hydroentanglinga fibrous structure may generate nonwovens with high softness andflexibility but may reduce the strength of the material. Such areduction in strength is undesirable for many applications of nonwovenfibrous structures, such as in a wipe application. Due to the nature ofcleansing tasks for which wipes are used, consumers prefer a wipe thathas a high amount of apparent bulk and strength associated with it. Toincrease the basis weight of the starting material, such that afterhydroentangling the material retains sufficient strength to be used as ababy wipe, would be prohibitively expensive.

The strength, thickness, flexibility and perceived softness may also beaffected by any hydro-molding (also known as hydro-embossing, hydraulicneedle-punching, etc.) of the nonwoven fibrous structure duringmanufacture. Hydro-molding is a known means of introducing textureand/or design to the nonwoven structures. As noted above, substratetexture may provide product differentiation, strength, softness andcleaning efficacy. Various images and graphics may be hydro-molded ontothe nonwoven fibrous structure. The images and graphics may be a singleimage or graphic, a group of images or graphics, a repeating pattern ofimages or graphics, a continuous image or graphic and combinationsthereof. It has been discovered, however, that the hydro-molding ofimages or graphics onto the nonwoven fibrous structure may detract fromthe desired strength of the fibrous structure.

During manufacture of the fibrous structure, the fibers generally orientin the Machine Direction when laid on a forming member. Suchfiber-orientation is common to various formation technologies such as,but not limited to, carding, air-laying, spunbonding, etc. The fibrousweb may then be conveyed over a molding member, such as a drum, belt,etc. that may comprise a molding pattern of raised areas, lowered areas,or combinations thereof interspersed thereon. The pattern may be used tomold the image, graphic or texture onto the fibrous web thereby creatinga molded fibrous structure. The resulting image, graphic, or texture onthe fibrous structure may be a molded element of the fibrous structure.

In a typical manufacturing process where the molding pattern is meant toconsist of discrete or disjoined elements of a repeating pattern, eachelement would be represented on the molding member as a complementarydiscrete element. Additionally, where the molding pattern is meant toincorporate at least one continuous element extending across the widthor along the length of the non-woven, the molding member must beconstructed so that the lowered areas of the molding pattern arecontinuous along either the length or the width of the fibrousstructure.

In a manufacturing process for textures incorporating a continuousmolding pattern, the continuous pattern may optionally be oriented ineither the Machine Direction (i.e. parallel to the dominantfiber-orientation direction) or in the Cross Direction (i.e.perpendicular to the dominant fiber-orientation). It has been found thathydro-molding a continuous molding pattern onto a fibrous structure, inwhich the lowered areas on the molding member are oriented in theMachine Direction, may produce a molded element on a fibrous structurethat is weak in strength because there are fewer fibers oriented in theCross Direction to provide continuity and, as such, strength across themolded element. A lack of strength can result in a molded fibrousstructure that may easily rip and fall apart.

Thus, there is a need to maintain the strength of a fibrous structureincorporating a continuous molded element. There remains a need toprovide a substrate from a molded fibrous structure.

SUMMARY OF THE INVENTION

The present invention relates to a method for making a molded fibrousstructure comprising a continuous molded element. The method comprisesthe steps of conveying a fibrous web along a machine direction over amolding member. The molding member comprises a pattern of raised areas,lowered areas or combinations thereof. Fluid is directed to impact thefibrous web causing the fibrous web to conform to the pattern on themolding member. The conformed fibrous web is also known as the moldedfibrous structure. At least a portion of the pattern is oriented in anon-Machine Direction.

At least a portion of the pattern is oriented from about 85 degrees toabout −85 degrees from the Cross Direction. In an alternate embodiment,at least a portion of the pattern is oriented from about 45 degrees toabout −45 degrees from the Cross Direction.

The pattern may comprise a width. The width of the pattern may be fromabout 0.03 cm to about 4.5 cm.

The continuous molded element may be one-dimensional.

The fluid may impact the fibrous web in a continuous flow or in anon-continuous flow.

The fibrous structure may further be converted into a substrate.

The present invention also relates to a molded fibrous structurecomprising a continuous molded element made according to the steps ofconveying a fibrous web along a machine direction over a molding memberand directing fluid to impact the fibrous web. The molding membercomprises a pattern of raised areas, lowered areas or combinationsthereof. The fluid causes the fibrous web to conform to the patternresulting in a molded fibrous structure. At least a portion of thepattern is oriented in a non-Machine Direction. A portion of the patternmay be oriented from about 85 degrees to about −85 degrees from theCross Direction.

A substrate may comprise a molded fibrous structure further comprising aone-dimensional continuous molded element.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of one embodiment of a molding member of thepresent invention.

FIG. 2 is a top view of one embodiment of a molding member of thepresent invention.

FIG. 3 is a top view of one embodiment of a molding member of thepresent invention shown with a fibrous web conveyed over the top of themolding member.

FIG. 4 is a top view of a molded fibrous structure of the presentinvention in which the continuous molded element extends from one edgeof the molded fibrous structure to the exact opposite edge of the moldedfibrous structure.

FIG. 5 is a top view of a molded fibrous structure of the presentinvention in which the continuous molded element extends from one edgeof the molded fibrous structure to the other edge of the molded fibrousstructure at an angle from the Cross Direction.

FIG. 6 is a plan view of an exemplary substrate made according to theprocess of the present invention.

FIG. 7 is a plan view of an exemplary substrate made according to theprocess of the present invention.

FIG. 8 is a plan view of an exemplary substrate made according to theprocess of the present invention.

FIG. 9 is a plan view of an exemplary substrate made according to theprocess of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

“Air-laying” refers herein to a process whereby air is used to separate,move, and randomly deposit fibers from a forming head to form acoherent, and largely isotropic fibrous web. Air laying equipment andprocesses are known in the art, and include Kroyer or Dan Web devices(suitable for wood pulp air laying, for example) and Rando webberdevices (suitable for staple fiber air laying, for example).

“Basis Weight” refers herein to the weight (measured in grams) of a unitarea (typically measured in square meters) of the fibrous structure,which unit area is taken in the plane of the fibrous structure. The sizeand shape of the unit area from which the basis weight is measured isdependent upon the relative and absolute sizes and shapes of the regionshaving different basis weights.

“Carding” refers herein to a mechanical process whereby clumps of fibersare substantially separated into individual fibers and simultaneouslymade into a coherent fibrous web. Carding is typically carried out on amachine that utilizes opposed moving beds or surfaces of fine, angled,closely spaced teeth or wires or their equivalent to pull and tease theclumps apart. The teeth of the two opposing surfaces typically areinclined in opposite directions and move at different speeds relative toeach other.

“Co-forming” refers herein to include a spun-melt process, in whichparticulate matter, typically cellulose-pulp, is entrained in thequenching air, so that the particulate matter becomes bound to thesemi-molten fibers during the fiber formation process.

“Continuous Molded Element” refers herein to a texture, pattern, image,graphic and combinations thereof on a molded fibrous structure that hasbeen imparted by hydro-molding. The hydro-molded texture, pattern,image, graphic and combinations thereof may extend, withoutinterruption, from a first edge of the molded fibrous structure to asecond edge of the molded fibrous structure. The continuous moldedelement, however, does not have to extend between exact oppositelocations of a first edge and a second edge of a substrate formed from amolded fibrous structure.

“Cross Direction” refers herein to a direction that is perpendicular tothe Machine Direction. This direction is carefully distinguished hereinbecause the mechanical properties of fibrous structures can differ,depending on how the fibrous structure is oriented. For purposes herein,the Cross Direction is noted as having an angle of zero degrees in theX-Direction of an XY grid. All angles will be noted from the referencepoint of the Cross Direction.

“Fibrous Structure” refers herein to an arrangement comprising aplurality of synthetic fibers, natural fibers, and combinations thereof.The synthetic and/or natural fibers may be layered, as known in the art,to form the fibrous structure. The fibrous structure may be a nonwoven.The fibrous structure may be formed from a fibrous web and may be aprecursor to a substrate.

“gsm” refers herein to “grams per square meter.”

“Machine Direction” refers herein to the direction in which a continuousfibrous structure is manufactured. Generally, fiber laying processessuch as carding, spunbonding, melt-blowing, etc., may result infiber-orientation parallel to the Machine Direction. This direction iscarefully distinguished herein because the mechanical properties offibrous structures can differ, depending on how the fibrous structure isoriented. For purposes herein, the Machine Direction is noted as havingan angle of ninety degrees from the Cross Direction.

“Molding Member” refers to a structural element that can be used as asupport for a fibrous web comprising a plurality of natural fibers, aplurality of synthetic fibers, and combinations thereof. The moldingmember may “mold” a desired geometry to the fibrous structure. Themolding member may comprise a molding pattern that may have the abilityto impart the pattern onto a fibrous web being conveyed thereon toproduce a molded fibrous structure comprising a continuous moldedelement.

“Nonwoven” refers to a fibrous structure made from an assembly ofcontinuous fibers, co-extruded fibers, non-continuous fibers andcombinations thereof, without weaving or knitting, by processes such asspunbonding, carding, melt-blowing, air-laying, wet-laying, co-form, orother such processes known in the art for such purposes. The nonwovenstructure may comprise one or more layers of such fibrous assemblies,wherein each layer may include continuous fibers, co-extruded fibers,non-continuous fibers and combinations thereof.

“One-dimensional Continuous Molded Element” refers herein to acontinuous molded element oriented primarily in the Machine Direction orthe Cross Direction. A continuous molded element is one-dimensional suchthat it does not intersect another continuous molded element.

“Spun-melt” refers herein to processes including both spun-laying andmelt-blowing. Spun-laying is a process whereby fibers are extruded froma melt during the making of the coherent web. The fibers are formed bythe extrusion of molten fiber material through fine capillary dies, andquenched, typically in air, prior to laying. In melt-blowing, theair-flow used during quenching is typically greater than in spun-laying,and the resulting fibers are typically finer, due to thedrawing-influence of the increased air-flow.

“Substrate” refers herein to a piece of material, generally non-wovenmaterial, used in cleaning or treating various surfaces, such as food,hard surfaces, inanimate objects, body parts, etc. For example, manycurrently available substrates may be intended for the cleansing of theperi-anal area after defecation. Other substrates may be available forthe cleansing of the face or other body parts. A “substrate” may also beknown as a “wipe” and both terms may be used interchangeably. Multiplesubstrates may be attached together by any suitable method to form amitt.

Fibrous Web

The fibrous web can be formed in any conventional fashion and may be anynonwoven web which is suitable for use in a hydromolding process. Thefibrous web may consist of any web, mat, or batt of loose fibers,disposed in relationship with one another in some degree of alignment,such as might be produced by carding, air-laying, spunbonding, and thelike. The fibrous web may be a precursor to a nonwoven molded fibrousstructure.

The fibers of the fibrous web, and subsequently the nonwoven moldedfibrous structure, may be any natural, cellulosic, and/or whollysynthetic material. Examples of natural fibers may include cellulosicnatural fibers, such as fibers from hardwood sources, softwood sources,or other non-wood plants. The natural fibers may comprise cellulose,starch and combinations thereof. Non-limiting examples of suitablecellulosic natural fibers include, but are not limited to, wood pulp,typical northern softwood Kraft, typical southern softwood Kraft,typical CTMP, typical deinked, corn pulp, acacia, eucalyptus, aspen,reed pulp, birch, maple, radiata pine and combinations thereof. Othersources of natural fibers from plants include, but are not limited to,albardine, esparto, wheat, rice, corn, sugar cane, papyrus, jute, reed,sabia, raphia, bamboo, sidal, kenaf, abaca, sunn, rayon (also known asviscose), lyocell, cotton, hemp, flax, ramie and combinations thereof.Yet other natural fibers may include fibers from other natural non-plantsources, such as, down, feathers, silk, cotton and combinations thereof.The natural fibers may be treated or otherwise modified mechanically orchemically to provide desired characteristics or may be in a form thatis generally similar to the form in which they can be found in nature.Mechanical and/or chemical manipulation of natural fibers does notexclude them from what are considered natural fibers with respect to thedevelopment described herein.

The synthetic fibers can be any material, such as, but not limited to,those selected from the group consisting of polyesters (e.g.,polyethylene terephthalate), polyolefins, polypropylenes, polyethylenes,polyethers, polyamides, polyesteramides, polyvinylalcohols,polyhydroxyalkanoates, polysaccharides, and combinations thereof.Further, the synthetic fibers can be a single component (i.e., singlesynthetic material or mixture makes up entire fiber), bi-component(i.e., the fiber is divided into regions, the regions including two ormore different synthetic materials or mixtures thereof and may includeco-extruded fibers and core and sheath fibers) and combinations thereof.It is also possible to use bicomponent fibers. These bicomponent fiberscan be used as a component fiber of the structure, and/or they may bepresent to act as a binder for the other fibers present in the fibrousstructure. Any or all of the synthetic fibers may be treated before,during, or after the process of the present invention to change anydesired properties of the fibers. For example, in certain embodiments,it may be desirable to treat the synthetic fibers before or duringprocessing to make them more hydrophilic, more wettable, etc.

In certain embodiments of the present invention, it may be desirable tohave particular combinations of fibers to provide desiredcharacteristics. For example, it may be desirable to have fibers ofcertain lengths, widths, coarseness or other characteristics combined incertain layers or separate from each other. The fibers may be ofvirtually any size and may have an average length from about 1 mm toabout 60 mm. Average fiber length refers to the length of the individualfibers if straightened out. The fibers may have an average fiber widthof greater than about 5 micrometers. The fibers may have an averagefiber width of from about 5 micrometers to about 50 micrometers. Thefibers may have a coarseness of greater than about 5 mg/100 m. Thefibers may have a coarseness of from about 5 mg/100 m to about 75 mg/100m.

The fibers may be circular in cross-section, dog bone shaped, delta(i.e., triangular cross-section), tri-lobal, ribbon, or other shapestypically produced as staple fibers. Likewise, the fibers can beconjugate fibers, such as bicomponent fibers. The fibers may be crimped,and may have a finish, such as a lubricant, applied.

The fibrous web of the present invention may have a basis weight ofbetween about 30, 40 or 45 gsm and about 50, 55, 60, 65, 70, or 75 gsm.Fibrous webs for use in the present invention may be available from theJ.W. Suominen Company of Finland, and sold under the FIBRELLA tradename. For example, FIBRELLA 3100 and FIBRELLA 3160 have been found to beuseful as fibrous webs in the present invention. FIBRELLA 3100 is a 62gsm nonwoven web comprising 50% 1.5 denier polypropylene fibers and 50%1.5 denier viscose fibers. FIBRELLA 3160 is a 58 gsm nonwoven webcomprising 60% 1.5 denier polypropylene fibers and 40% 1.5 denierviscose fibers. In both of these commercially available fibrous webs,the average fiber length is about 38 mm. Additional fibrous websavailable from Suominen may include a 62 gsm nonwoven web comprising 60%polypropylene fibers and 40% viscose fibers; a fibrous web comprising abasis weight from about 50 or 55 to about 58 or 62 and comprising 60%polypropylene fibers and 40% viscose fibers; and a fibrous webcomprising a basis weight from about 62 to about 70 or 75 gsm. Thelatter fibrous web may comprise 60% polypropylene fibers and 40% viscosefibers.

Molded Fibrous Structure

The fibrous web may be the precursor to a fibrous structure. The fibrousweb may be conveyed over a molding member during or after manufacture.The molding member may comprise a molding pattern of raised areas,lowered areas, and combinations thereof interspersed thereon. Raisedareas may also incorporate solid areas. Lowered areas may alsoincorporate void areas. The molding member may impart the pattern ontothe fibrous web during a hydro-molding process step thereby forming afibrous structure comprising a molded element.

The molding pattern of raised and/or lowered areas may comprise images,graphics and combinations thereof and may comprise logos, indicia,trademarks, geometric patterns, images of the surfaces that a substrate(as discussed herein) is intended to clean (i.e., infant's body, face,etc.) and combinations thereof. They may be utilized in a random oralternating manner or they may be used in a consecutive, repeatingmanner. The images, graphics and combinations thereof may be a singleimage or graphic, a group of images or graphics, a repeating pattern ofimages or graphics, a continuous image or graphic, and combinationsthereof.

The molded fibrous structure may comprise a continuous molded element.The continuous molded element may extend from a first edge of thefibrous structure to a second edge of the fibrous structure and therebyform a continuous molded element. The continuous molded element mayextend from a first location on a first edge of the fibrous structure toan exact opposing second location on a second edge of the fibrousstructure. Alternatively, the continuous molded element may extend froma first location on a first edge of the fibrous structure to a secondlocation on a second edge of the fibrous structure wherein the secondlocation is not an exact opposite location from the originatinglocation.

At least a portion of the continuous molded element on the fibrousstructure may be oriented in a non-Machine Direction. The molded elementneed not be oriented solely at a position of zero degrees relative tothe Cross Direction. The molded element may comprise portions molded inthe Machine Direction and portions molded in the Cross Direction. Thecontinuous molded element may be oriented at various angles on thefibrous structure. The angle orientation of the continuous moldedelement may be measured from the Cross Direction comprising an angle ofzero degrees. The continuous molded element may be oriented on thefibrous structure at an angle of about 15, 30, 45, 60, 75 or 85 degrees.Alternatively, the continuous molded element may be oriented on thefibrous structure at an angle of about −15, −30, −45, −60, −75, −85degrees. The continuous molded element may be oriented on the fibrousstructure at any angle from about 85 degrees to about −85 degrees. Thecontinuous molded element may be oriented on the fibrous structure atany angle from about 75, 60, 45, 30, or 15 degrees to about −15, −30,−45, −60, or −75 degrees.

The continuous molded element may comprise a width. The width of thecontinuous molded element may be any desired width, provided that thewidth of the continuous molded element is not so great as to cause thecontinuous molded element to contact another continuous molded element.The width of the continuous molded element may be measured from the topedge of the continuous molded element to the bottom edge of thecontinuous molded element. The width may be greater than about 0.03 cm.The width may be less than about 4.5 cm. The width of the continuousmolded element may range from about 0.03, 0.05, 0.1, 0.3, 0.5, 1 or 1.5cm to about 2, 2.5, 3, 3.5, 4, or 4.5 cm. Unmolded areas may existbetween each continuous molded element so as to provide separationbetween each continuous molded element.

The fibrous structure of the present invention may take a number ofdifferent forms. The fibrous structure may comprise 100% syntheticfibers or may be a combination of synthetic fibers and natural fibers.In one embodiment of the present invention, the fibrous structure mayinclude one or more layers of a plurality of synthetic fibers mixed witha plurality of natural fibers. The synthetic fiber/natural fiber mix maybe relatively homogeneous in that the different fibers may be dispersedgenerally randomly throughout the layer. The fiber mix may be structuredsuch that the synthetic fibers and natural fibers may be disposedgenerally non-randomly. In one embodiment, the fibrous structure mayinclude at least one layer comprising a plurality of natural fibers andat least one adjacent layer comprising a plurality of synthetic fibers.In another embodiment, the fibrous structure may include at least onelayer that comprises a plurality of synthetic fibers homogeneously mixedwith a plurality of natural fibers and at least one adjacent layer thatcomprises a plurality of natural fibers. In an alternate embodiment, thefibrous structure may include at least one layer that comprises aplurality of natural fibers and at least one adjacent layer that maycomprise a mixture of a plurality of synthetic fibers and a plurality ofnatural fibers in which the synthetic fibers and/or natural fibers maybe disposed generally non-randomly. Further, one or more of the layersof mixed natural fibers and synthetic fibers may be subjected tomanipulation during or after the formation of the fibrous structure todisperse the layer or layers of mixed synthetic and natural fibers in apredetermined pattern or other non-random pattern.

The fibrous structure may further comprise binder materials. The fibrousstructure may comprise from about 0.01% to about 1%, 3%, or 5% by weightof a binder material selected from the group consisting of permanent wetstrength resins, temporary wet strength resins, dry strength resins,retention aid resins and combinations thereof.

If permanent wet strength is desired, the binder materials may beselected from the group consisting of polyamide-epichlorohydrin,polyacrylamides, styrene-butadiene latexes, insolubilized polyvinylalcohol, ureaformaldehyde, polyethyleneimine, chitosan polymers andcombinations thereof.

If temporary wet strength is desired, the binder materials may be starchbased. Starch based temporary wet strength resins may be selected fromthe group consisting of cationic dialdehyde starch-based resin,dialdehyde starch and combinations thereof. The resin described in U.S.Pat. No. 4,981,557, issued Jan. 1, 1991 to Bjorkquist may also be used.

If dry strength is desired, the binder materials may be selected fromthe group consisting of polyacrylamide, starch, polyvinyl alcohol, guaror locust bean gums, polyacrylate latexes, carboxymethyl cellulose andcombinations thereof.

A latex binder may also be utilized. Such a latex binder may have aglass transition temperature from about 0° C., −10° C., or −20° C. toabout −40° C., −60° C., or −80° C. Examples of latex binders that may beused include polymers and copolymers of acrylate esters, referred togenerally as acrylic polymers, vinyl acetate-ethylene copolymers,styrene-butadiene copolymers, vinyl chloride polymers, vinylidenechloride polymers, vinyl chloride-vinylidene chloride copolymers,acrylo-nitrile copolymers, acrylic-ethylene copolymers and combinationsthereof. The water emulsions of these latex binders usually containsurfactants. These surfactants may be modified during drying and curingso that they become incapable of rewetting.

Methods of application of the binder materials may include aqueousemulsion, wet end addition, spraying and printing. At least an effectiveamount of binder may be applied to the fibrous structure. Between about0.01% and about 1.0%, 3.0% or 5.0% may be retained on the fibrousstructure, calculated on a dry fiber weight basis. The binder may beapplied to the fibrous structure in an intermittent pattern generallycovering less than about 50% of the surface area of the structure. Thebinder may also be applied to the fibrous structure in a pattern togenerally cover greater than about 50% of the fibrous structure. Thebinder material may be disposed on the fibrous structure in a randomdistribution. Alternatively, the binder material may be disposed on thefibrous structure in a non-random repeating pattern.

Additional information relating to the fibrous structure may be found inU.S. Patent Application No. 2004/0154768, filed by Trokhan et al. andpublished Aug. 12, 2004, US Patent Application No. 2004/0157524, filedby Polat et al. and published Aug. 12, 2004, U.S. Pat. No. 4,588,457,issued to Crenshaw et al., May 13, 1986, U.S. Pat. No. 5,397,435, issuedto Ostendorf et al., Mar. 14, 1995 and U.S. Pat. No. 5,405,501, issuedto Phan et al., Apr. 11, 1995.

Substrate

The molded fibrous structure, as described above, may be utilized toform a substrate. The molded fibrous structure may continue to beprocessed in any method known to one of ordinary skill to convert themolded fibrous structure to a substrate comprising at least onecontinuous molded element. This may include, but is not limited to,slitting, cutting, perforating, folding, stacking, interleaving,lotioning and combinations thereof. The substrate may comprise acontinuous molded element extending from a first location on a firstedge to a second location on a second edge. The second location may beexactly opposite to the first location or may be at a position on thesecond edge such that the second location is not exactly opposite fromthe first location. In one embodiment, the second location may be on thesame substrate as the first location or may be on a subsequent substratethat does not also comprise the first location. Variations in moldingand processing may produce a substrate in which the continuous moldedelement that, while extending in a non-Machine Direction, does notextend from a location on one edge to a mirror image location on anotheredge. As noted above, the pattern on the molding member may be orientedat an angle as measured from the Cross Direction. Thus, the continuousmolded element may be oriented at an angle between 85° and −85° relativeto the Cross Direction on the substrate.

The material of which a substrate is made from should be strong enoughto resist tearing during manufacture and normal use, yet still providesoftness to the user's skin, such as a child's tender skin.Additionally, the material should be at least capable of retaining itsform for the duration of the user's cleansing experience.

Substrates may be generally of sufficient dimension to allow forconvenient handling. Typically, the substrate may be cut and/or foldedto such dimensions as part of the manufacturing process. In someinstances, the substrate may be cut into individual portions so as toprovide separate wipes which are often stacked and interleaved inconsumer packaging. In other embodiments, the substrates may be in a webform where the web has been slit and folded to a predetermined width andprovided with means (e.g., perforations) to allow individual wipes to beseparated from the web by a user. Suitably, the separate wipes may havea length between about 100 mm and about 250 mm and a width between about140 mm and about 250 mm. In one embodiment, the separate wipe may beabout 200 mm long and about 180 mm wide.

The material of the substrate may generally be soft and flexible,potentially having a structured surface to enhance its performance. Itis also within the scope of the present invention that the substrate mayinclude laminates of two or more materials. Commercially availablelaminates, or purposely built laminates would be within the scope of thepresent invention. The laminated materials may be joined or bondedtogether in any suitable fashion, such as, but not limited to,ultrasonic bonding, adhesive, glue, fusion bonding, heat bonding,thermal bonding, hydroentangling and combinations thereof. In anotheralternative embodiment of the present invention the substrate may be alaminate comprising one or more layers of nonwoven materials and one ormore layers of film. Examples of such optional films, include, but arenot limited to, polyolefin films, such as, polyethylene film. Anillustrative, but non-limiting example of a nonwoven sheet member whichis a laminate of a 16 gsm nonwoven polypropylene and a 0.8 mm 20 gsmpolyethylene film.

The substrate materials may also be treated to improve the softness andtexture thereof. The substrate may be subjected to various treatments,such as, but not limited to, physical treatment, such as ring rolling,as described in U.S. Pat. No. 5,143,679; structural elongation, asdescribed in U.S. Pat. No. 5,518,801; consolidation, as described inU.S. Pat. Nos. 5,914,084, 6,114,263, 6,129,801 and 6,383,431; stretchaperturing, as described in U.S. Pat. Nos. 5,628,097, 5,658,639 and5,916,661; differential elongation, as described in WO Publication No.2003/0028165A1; and other solid state formation technologies asdescribed in U.S. Publication No. 2004/0131820A1 and U.S. PublicationNo. 2004/0265534A1, zone activation, and the like; chemical treatment,such as, but not limited to, rendering part or all of the substratehydrophobic, and/or hydrophilic, and the like; thermal treatment, suchas, but not limited to, softening of fibers by heating, thermal bondingand the like; and combinations thereof.

The substrate may have a basis weight of at least about 30 grams/m². Thesubstrate may have a basis weight of at least about 40 grams/m². In oneembodiment, the substrate may have a basis weight of at least about 45grams/m². In another embodiment, the substrate basis weight may be lessthan about 75 grams/m². In another embodiment, substrates may have abasis weight between about 40 grams/m² and about 75 grams/m², and in yetanother embodiment a basis weight between about 40 grams/m² and about 65grams/m². The substrate may have a basis weight between about 30, 40, or45 and about 50, 55, 60, 65, 70 or 75 grams/m².

A suitable substrate may be a carded nonwoven comprising a 40/60 blendof viscose fibers and polypropylene fibers having a basis weight of 58grams/m² as available from Suominen of Tampere, Finland as FIBRELLA3160. Another suitable material for use as a substrate may be SAWATEX2642 as available from Sandler AG of Schwarzenbach/Salle, Germany. Yetanother suitable material for use as a substrate may have a basis weightof from about 50 grams/m² to about 60 grams/m² and have a 20/80 blend ofviscose fibers and polypropylene fibers. The substrate may also be a60/40 blend of pulp and viscose fibers. The substrate may also be formedfrom any of the following fibrous webs such as those available from theJ.W. Suominen Company of Finland, and sold under the FIBRELLA tradename. For example, FIBRELLA 3100 is a 62 gsm nonwoven web comprising 50%1.5 denier polypropylene fibers and 50% 1.5 denier viscose fibers. Inboth of these commercially available fibrous webs, the average fiberlength is about 38 mm. Additional fibrous webs available from Suominenmay include a 62 gsm nonwoven web comprising 60% polypropylene fibersand 40% viscose fibers; a fibrous web comprising a basis weight fromabout 50 or 55 to about 58 or 62 and comprising 60% polypropylene fibersand 40% viscose fibers; and a fibrous web comprising a basis weight fromabout 62 to about 70 or 75 gsm. The latter fibrous web may comprise 60%polypropylene fibers and 40% viscose fibers.

In one embodiment of the present invention the surface of substrate maybe essentially flat. In another embodiment of the present invention thesurface of the substrate may optionally contain raised and/or loweredportions. These can be in the form of logos, indicia, trademarks,geometric patterns, images of the surfaces that the substrate isintended to clean (i.e., infant's body, face, etc.). They may berandomly arranged on the surface of the substrate or be in a repetitivepattern of some form.

In another embodiment of the present invention the substrate may bebiodegradable. For example, the substrate could be made from abiodegradable material such as a polyesteramide, or a high wet strengthcellulose.

Composition

The substrate may further comprise a soothing and/or cleansingcomposition. The composition impregnating the substrate is commonly andinterchangeably called lotion, soothing lotion, soothing composition,oil-in-water emulsion composition, emulsion composition, emulsion,cleaning or cleansing lotion or composition. All those terms are herebyused interchangeably. The composition may generally comprise thefollowing optional ingredients: emollients, surfactants and/or anemulsifiers, soothing agents, rheology modifiers, preservatives, or morespecifically a combination of preservative compounds acting together asa preservative system and water.

It is to be noted that some compounds can have a multiple function andthat all compounds are not necessarily present in the composition of theinvention. The composition may be a oil-in-water emulsion. The pH of thecomposition may be from about pH 3, 4 or 5 to about pH 7, 7.5, or 9.

Emollient:

In the substrates of the present invention, emollients may (1) improvethe glide of the substrate on the skin, by enhancing the lubrication andthus decreasing the abrasion of the skin, (2) hydrate the residues (forexample, fecal residues or dried urine residues), thus enhancing theirremoval from the skin, (3) hydrate the skin, thus reducing its drynessand irritation while improving its flexibility under the wipingmovement, and (4) protect the skin from later irritation (for example,caused by the friction of underwear) as the emollient is deposited ontothe skin and remains at its surface as a thin protective layer.

In one embodiment, emollients may be silicone based. Silicone-basedemollients may be organo-silicone based polymers with repeating siloxane(Si—O) units. Silicone-based emollients of the present invention may behydrophobic and may exist in a wide range of possible molecular weights.They may include linear, cyclic and cross-linked varieties. Siliconeoils may be chemically inert and may have a high flash point. Due totheir low surface tension, silicone oils may be easily spreadable andmay have high surface activity. Examples of silicon oil may include:cyclomethicones, dimethicones, phenyl-modified silicones, alkyl-modifiedsilicones, silicones resins and combinations thereof.

Other useful emollients can be unsaturated esters or fatty esters.Examples of unsaturated esters or fatty esters of the present inventioninclude: caprylic capric triglycerides in combination withBis-PEG/PPG-16/16 PEG/PPG-16/16 dimethicone and C₁₂-C₁₅ alkylbenzoateand combinations thereof.

A relatively low surface tension may act more efficiently in thecomposition. Surface tension lower than about 35 mN/m, or even lowerthan about 25 mN/m. In certain embodiments, the emollient may have amedium to low polarity. Also, the emollient of the present invention mayhave a solubility parameter between about 5 and about 12, or evenbetween about 5 and about 9. The basic reference of the evaluation ofsurface tension, polarity, viscosity and spreadability of emollient canbe found under Dietz, T., Basic properties of cosmetic oils and theirrelevance to emulsion preparations. SÖFW-Journal, July 1999, pages 1-7.

Emulsifier/Surfactant:

The composition may also include an emulsifier such as those formingoil-in-water emulsions. The emulsifier can be a mixture of chemicalcompounds and include surfactants. The preferred emulsifiers are thoseacting as well as a surfactant. For the purpose of this document, theterms emulsifiers and surfactants are thereafter used interchangeably.The emulsifier may be a polymeric emulsifier or a non polymeric one.

The emulsifier may be employed in an amount effective to emulsify theemollient and/or any other non-water-soluble oils that may be present inthe composition, such as an amount ranging from about 0.5%, 1%, or 4% toabout 0.001%, 0.01%, or 0.02% (based on the weight emulsifiers over theweight of the composition). Mixtures of emulsifiers may be used.

Emulsifiers for use in the present invention may be selected from thegroup consisting of alkylpolylglucosides, decylpolyglucoside, fattyalcohol or alkoxylated fatty alcohol phosphate esters (e.g.,trilaureth-4 phosphate), sodium trideceth-3 carboxylate, or a mixture ofcaprylic capric triglyceride and Bis-PEG/PPG-16/16 PEG/PPG-16/16dimethicone, polysorbate 20, and combinations thereof.

Rheology Modifier

Rheology modifiers are compounds that increase the viscosity of thecomposition at lower temperatures as well as at process temperatures.Each of these materials may also provide “structure” to the compositionsto prevent settling out (separation) of insoluble and partially solublecomponents. Other components or additives of the compositions may affectthe temperature viscosity/rheology of the compositions.

In addition to stabilizing the suspension of insoluble and partiallysoluble components, the rheology modifiers of the invention may alsohelp to stabilize the composition on the substrate and enhance thetransfer of lotion to the skin. The wiping movement may increase theshear and pressure therefore decreasing the viscosity of the lotion andenabling a better transfer to the skin as well as a better lubricationeffect.

Additionally, the rheology modifier may help to preserve a homogeneousdistribution of the composition within a stack of substrates. Anycomposition that is in fluid form has a tendency to migrate to the lowerpart of the wipes stack during prolonged storage. This effect creates anupper zone of the stack having less composition than the bottom part.This is seen as a sign of relatively low quality by the users.

Preferred rheology modifiers may exhibit low initial viscosity and highyield. Particularly suited are rheology modifiers such as, but notlimited to:

-   -   Blends of material as are available from Uniqema GmbH&Co. KG, of        Emmerich, Germany under the trade name ARLATONE. For instance,        ARLATONE V-175 which is a blend of sucrose palmitate, glyceryl        stearate, glyceryl stearate citrate, sucrose, mannan, and        xanthan gum and Arlatone V-100 which is a blend of steareth-100,        steareth-2, glyceryl stearate citrate, sucrose, mannan and        xanthan gum.    -   Blends of materials as are available from Seppic France of        Paris, France as SIMULGEL. For example, SIMULGEL NS which        comprises a blend of hydroxyethylacrylate/sodium        acryloyldimethyl taurate copolymer and squalane and polysorbate        60, sodium acrylate/sodium acryloyldimethyltaurate copolymer and        polyisobutene and caprylyl capryl glucoside, acrylate        copolymers, such as but not limited to acrylates/acrylamide        copolymers, mineral oil, and polysorbate 85.    -   Acrylate homopolymers, acrylate crosspolymers, such as but not        limited to, Acrylate/C10-30 Alkyl Acrylate crosspolymers,        carbomers, such as but not limited to acrylic acid cross linked        with one or more allyl ether, such as but not limited to allyl        ethers of pentaerythritol, allyl ethers of sucrose, allyl ethers        of propylene, and combinations thereof as are available are        available as the Carbopol® 900 series from Noveon, Inc. of        Cleveland, Ohio (e.g., Carbopol® 954).    -   Naturally occurring polymers such as xanthan gum,        galactoarabinan and other polysaccharides.    -   Combinations of the above rheology modifiers.

Examples, of commercially available rheology modifiers include but arenot limited to, Ultrez-10, a carbomer, and Pemulen TR-2, an acrylatecrosspolymers, both of which are available from Noveon, Cleveland Ohio,and Keltrol, a xanthan gum, available from CP Kelco San Diego Calif.

Rheology modifiers imparting a low viscosity may be used. Low viscosityis understood to mean viscosity of less than about 10,000 cps at about25 degrees Celsius of a 1% aqueous solution. The viscosity may be lessthan about 5,000 cps under the same conditions. Further, the viscositymay be less than about 2000 cps or even less than about 1,000 cps. Othercharacteristics of emulsifiers may include high polarity and a non-ionicnature.

Rheology modifiers, when present may be used in the present invention ata weight/weight % (w/w) from about 0.01%, 0.015%, or 0.02% to about 1%,2%, or 3%.

Preservative

The need to control microbiological growth in personal care products isknown to be particularly acute in water based products such asoil-in-water emulsions and in pre-impregnated substrates such as babywipes. The composition may comprise a preservative or more preferably acombination of preservatives acting together as a preservative system.Preservatives and preservative systems are used interchangeably in thepresent document to indicate one unique or a combination of preservativecompounds. A preservative is understood to be a chemical or naturalcompound or a combination of compounds reducing the growth ofmicroorganisms, thus enabling a longer shelf life for the pack of wipes(opened or not opened) as well as creating an environment with reducedgrowth of microorganisms when transferred to the skin during the wipingprocess.

Preservatives of the present invention can be defined by 2 keycharacteristics: (i) activity against a large spectrum ofmicroorganisms, that may include bacteria and/or molds and/or yeast,preferably all three categories of microorganisms together and (2)killing efficacy and/or the efficacy to reduce the growth rate at aconcentration as low as possible.

The spectrum of activity of the preservative of the present inventionmay include bacteria, molds and yeast. Ideally, each of suchmicroorganisms are killed by the preservative. Another mode of action tobe contemplated is the reduction of the growth rate of themicroorganisms without active killing. Both actions however result in adrastic reduction of the population of microorganisms.

Suitable materials include, but are not limited to a methylol compound,or its equivalent, an iodopropynyl compound and mixtures thereof.Methylol compounds release a low level of formaldehyde when in watersolution that has effective preservative activity. Exemplary methylolcompounds include but are not limited to: diazolidinyl urea (GERMALL® IIas is available from International Specialty Products of Wayne, N.J.)N-[1,3-bis(hydroxy-methyl)-2,5-dioxo-4-imidazolidinyl]-N,N′-bis(hydroxymethyl)urea, imidurea (GERMALL® 115 as is available from InternationalSpecialty Products of Wayne, N.J.), 1,1-methylenebis[3-[3-(hydroxymethyl)-2,5-dioxo-4-imidazolidinyl]urea];1,3-dimethylol-5,5-dimethyl hydantoin (DMDMH), sodium hydroxymethylglycinate (SUTTOCIDE® A as is available from International SpecialtyProducts of Wayne, N.J.), and glycine anhydride dimethylol (GADM).Methylol compounds can be effectively used at concentrations (100%active basis) between about 0.025% and about 0.50%. A preferredconcentration (100% basis) is about 0.075%. The iodopropynyl compoundprovides antifungal activity. An exemplary material is iodopropynylbutyl carbamate as is available from Clariant UK, Ltd. of Leeds, TheUnited Kingdom as NIPACIDE IPBC. A particularly preferred material is3-iodo-2-propynylbutylcarbamate. Iodopropynyl compounds can be usedeffectively at a concentration between about 0% and about 0.05%. Apreferred concentration is about 0.009%. A particularly preferredpreservative system of this type comprise a blend of a methylol compoundat a concentration of about 0.075% and a iodopropynyl compound at aconcentration of about 0.009%.

In another embodiment, the preservative system may comprise simplearomatic alcohols (e.g., benzyl alcohol). Materials of this type haveeffective anti bacterial activity. Benzyl alcohol is available fromSymrise, Inc. of Teterboro, N.J.

In another embodiment, the preservative may be a paraben antimicrobialselected from the group consisting of methylparaben, ethylparaben,propylparaben, butylparaben, isobutylparaben or combinations thereof.

Chelators (e.g., ethylenediamine tetraacetic acid and its salts) mayalso be used in preservative systems as a potentiator for otherpreservative ingredients.

The preservative composition can moreover provide a broad anti-microbialeffect without the use of formaldehyde donor derived products. Thesetraditional formaldehyde based preservative products have been widelyused in the past but are now no longer permitted in a number ofcountries for products intended for human use.

Optional Components of the Composition:

The composition may optionally include adjunct ingredients. Possibleadjunct ingredients may be selected from a wide range of additionalingredients such as, but not limited to soothing agents, perfumes andfragrances, texturizers, colorants, medically active ingredients, inparticular healing actives and skin protectants.

Optional soothing agents may be (a) ethoxylated surface activecompounds, more preferably those having an ethoxylation number belowabout 60, (b) polymers, more preferably polyvinylpyrrolidone (PVP)and/or N-vinylcaprolactam homopolymer (PVC), and (c) phospholipids, morepreferably phospholipids complexed with other functional ingredients ase.g., fatty acids, organosilicones.

The soothing agents may be selected from the group comprising PEG-40hydrogenated castor oil, sorbitan isostearate, isoceteth-20, sorbeth-30,sorbitan monooleate, coceth-7, PPG-1-PEG-9 lauryl glycol ether, PEG-45palm kernel glycerides, PEG-20 almond glycerides, PEG-7 hydrogenatedcastor oil, PEG-50 hydrogenated castor oil, PEG-30 castor oil, PEG-24hydrogenated lanolin, PEG-20 hydrogenated lanolin, PEG-6 caprylic/capricglycerides, PPG-1 PEG-9 lauryl glycol ether, lauryl glucosidepolyglyceryl-2 dipolyhydroxystearate, sodium glutamate,polyvinylpyrrolidone, N-vinylcaprolactam homopolymer, sodium cocoPG-dimonium chloride phosphate, linoleamidopropyl PG-dimonium chloridephosphate, dodium borageamidopropyl PG-dimonium chloride phosphate,N-linoleamidopropyl PG-dimonium chloride phosphate dimethicone,cocamidopropyl PG-dimonium chloride phosphate, stearamidopropylPG-dimonium chloride phosphate and stearamidopropyl PG-dimonium chloridephosphate (and) cetyl alcohol, and combinations thereof. A particularlypreferred soothing agent is PEG-40 hydrogenated castor oil as isavailable from BASF of Ludwigshafen, Germany as Cremophor CO 40.

Method of Making Molded Fibrous Structure

Generally, the process of the present invention for making a fibrousstructure may be described in terms of initially forming a fibrous webhaving a plurality of synthetic fibers. A plurality of natural fibersmay also be disposed in the fibrous web. Layered deposition of thefibers, synthetic and natural, is also contemplated by the presentinvention. The fibrous web can be formed in any conventional fashion andmay be any nonwoven web that may be suitable for use in a hydromoldingprocess. The fibrous web may consist of any web, mat, or batt of loosefibers disposed in any relationship with one another in any degree ofalignment, such as might be produced by carding, air-laying, spunmelting(including meltblowing and spunlaying), coforming and the like.

In the present invention, conducting the carding, spunmelting,spunlaying, meltblowing, coforming, or air-laying or other bondingprocesses concurrently with the fibers contacting a forming member mayproduce a fibrous web. The process of the present invention may involvesubjecting the fibrous web to a hydroentanglement process while thefibrous web is in contact with the forming member. The hydroentanglementprocess (also known as spunlacing or spunbonding) is a known process ofproducing nonwoven webs, and involves laying down a matrix of fibers,for example as a carded web or an air-laid web, and entangling thefibers to form a coherent web. Entangling is typically accomplished byimpinging the matrix of fibers with high pressure liquid (typicallywater) from at least one, at least two, or a plurality ofsuitably-placed water jets. The pressure of the liquid jets, as well asthe orifice size and the energy imparted to the fibrous structurepreform by the water jets, may be the same as those of a conventionalhydroentangling process. Typically, entanglement energy may be about 0.1kwh/kg. While other fluids can be used as the impinging medium, such ascompressed air, water is the preferred medium. The fibers of the web arethus entangled, but not physically bonded one to another. The fibers ofa hydroentangled web, therefore, have more freedom of movement thanfibers of webs formed by thermal or chemical bonding. Particularly whenlubricated by wetting as a pre-moistened wet wipe, such spunlaced websprovide webs having very low bending torques and low moduli, therebyachieving softness and suppleness.

Additional information on hydroentanglement can be found in U.S. Pat.Nos. 3,485,706 issued on Dec. 23, 1969, to Evans; 3,800,364 issued onApr. 2, 1974, to Kalwaites; 3,917,785 issued on Nov. 4, 1975, toKalwaites; 4,379,799 issued on Apr. 12, 1983, to Holmes; 4,665,597issued on May 19, 1987, to Suzuki; 4,718,152 issued on Jan. 12, 1988, toSuzuki; 4,868,958 issued on Sep. 26, 1989, to Suzuki; 5,115,544 issuedon May 26, 1992, to Widen; and 6,361,784 issued on Mar. 26, 2002, toBrennan.

After the fibrous web has been formed, it can be subjected to additionalprocess steps, such as, hydro-molding (also known as molding,hydro-embossing, hydraulic needle-punching, etc.). FIG. 1 illustrates aside view of a molding member 10 with a fibrous web 30 being conveyedover the top of the molding member 10. A single jet 40, or multiplejets, may be utilized. Water or any other appropriate fluid medium maybe ejected from the jet 40 to impact the fibrous web 30. The fluid mayimpact the fibrous web in a continuous flow or non-continuous flow. Themolding member 10 may comprise a molding pattern (as exemplified in FIG.2). The molding pattern may comprise raised areas, lowered areas, andcombinations thereof. As the fluid from the jet(s) 40 impacts thefibrous web 30, the fibrous web 30 may conform to the molding pattern.The fluid may “push” portions of the fibrous web 30 into lowered areasof the pattern. The result may be a molded fibrous structure 36.

FIG. 2 illustrates a molding member 10 comprising an exemplary moldingpattern 20 extending in a non-Machine Direction. It should be noted thatthe pattern may take any form, design, shape, image, graphic, andcombinations thereof as desired. The molding member 10 may comprise apattern 20 of raised areas, lowered areas, and combinations thereof.Raised areas may also incorporate solid areas. Lowered areas may alsoincorporate void areas. The pattern 20 may extend from a first side 12to a second side 14 of the molding member 10. The pattern 20 may have awidth “w” as deemed appropriate for molding onto a fibrous structure.The width of the pattern 20 may range from about 0.03, 0.05, 0.1, 0.3,0.5, 1 or 1.5 cm to about 2, 2.5, 3, 3.5, 4, or 4.5 cm. Unmolded space22 may exist between each pattern 20 so as to provide separation betweeneach pattern 20.

FIG. 2 illustrates that the pattern 20 may be oriented at an angle ofabout zero degrees. Such a pattern 20 may be considered to be in theCross Direction. However, it should be realized that the pattern 20 neednot be in the Cross Direction. At least a portion of the pattern may beoriented in a non-Machine Direction. While the pattern may have aportion oriented in the Machine Direction, the orientation of thepattern should not be such that the pattern will intersect any otherpattern. The pattern 20 may orient at an angle of about 15, 30, 45, 60,75 or 85 degrees. Alternatively, the pattern 20 may orient at an angleof about −15, −30, −45, −60, −75 or −85 degrees. The pattern 20 may beoriented at any angle from about 85 degrees to about −85 degrees. Thepattern 20 may be oriented at any angle from about 75, 60, 45, 30 or 15degrees to about −15, −30, −45, −60, or −75 degrees. The angleorientation of the pattern is measured from the Cross Directioncomprising an angle of zero degrees.

FIG. 3 illustrates a top view of a molding member 10 with a fibrous web30 conveyed over the top of the molding member 10. As the pattern ishydro-molded onto the fibrous web 30, the pattern 20 may extend from afirst location 37 of a first edge 32 to a second location 38 of a secondedge 34 of the resulting molded fibrous structure 36. As such, thepattern 20 may be considered to be continuous. The pattern 20 may bemolded onto the fibrous web 30 by a hydromolding process. In such aprocess, fluid may be directed towards the fibrous web 30 in such asmanner as to impact the fibrous web 30 causing it to conform to thepattern 20 on the molding member 10.

FIG. 4 illustrates a molded fibrous structure 50 comprising aone-dimensional continuous molded element 58 produced by a moldingpattern on a molding member. The one-dimensional continuous moldedelement 58 extends from a first location 56 on a first edge 52 to asecond location 57 on a second edge 54. In FIG. 4, the continuous moldedelement 58 extends to exact opposite locations, 56 and 57, in the CrossDirection of the first and second edges, 52 and 54, respectively.

FIG. 5 illustrates a molded fibrous structure 60 comprising aone-dimensional continuous molded element 68 produced by a moldingpattern on a molding member. The one-dimensional continuous moldedelement 68 extends from a first location 66 on a first edge 62 to asecond location 67 on a second edge 64. In FIG. 5, at least a portion ofthe continuous molded element 68 extends in a non-Machine Direction. Thecontinuous molded element 68 is illustrated extending at an angle fromthe Cross Direction and therefore does not extend to exact oppositelocations, 66 and 67, on the first and second edges, 62 and 64,respectively.

Following the hydromolding of the pattern onto the fibrous web, theresulting molded fibrous structure may continue to be processed in anymethod known to one of ordinary skill to covert the molded fibrousstructure to a substrate suitable for use as a wipe. This may include,but is not limited to, slitting, cutting, perforating, folding,stacking, interleaving, lotioning and combinations thereof.

FIG. 6 illustrates an idealized plan view of a substrate 72 madeaccording to the present invention. As can be seen, a one-dimensionalcontinuous molded element 70 may extend from one edge 71 of thesubstrate 72 to the opposite edge 73 of the substrate 72 in the CrossDirection. FIG. 7 illustrates an alternate exemplary one-dimensionalcontinuous molded element 74 extending from one edge 75 of a substrate76 to an opposite edge 77 of the substrate 76. FIG. 8 illustratesanother alternate exemplary one-dimensional continuous molded element 82extending from one edge 84 of a substrate 80 to an opposite edge 86 ofthe substrate 80.

FIG. 9 illustrates another idealized plan view of a substrate 90 madeaccording to the present invention. As can be seen, a one-dimensionalcontinuous molded element 92 may extend from one edge 94 of thesubstrate 90 to the opposite edge 96 of the substrate 90 in anon-Machine Direction. It should be noted that the substrate 90 has beenrotated. The Machine Direction (MD) and the Cross Direction (CD) arenoted for orientation purposes. During manufacture, in the conversion ofa molded fibrous structure to a substrate, such as substrate 90, theresulting substrate need not have a molded element extending to exactopposite locations on the substrate. As the pattern on the moldingelement may extend at an angle as measured from the Cross Direction, theresulting molded element 92 on the substrate 90 may also extend at anangle as measured from the Cross Direction. Additionally, anymanufacturing steps such as cutting, folding, interleaving, slitting,perforating, stacking, lotioning and combinations thereof, may shift themolded fibrous structure away from the exact Machine Direction such thatthe resulting substrate comprises a molded element extending as an angleas measured from the Cross Direction.

By molding the fibrous web, it can gain additional aesthetics, makingthe fibrous web particularly suitable and pleasing for use as a wipe.Moreover, besides better aesthetics, other beneficial physicalcharacteristics may be imparted to the fibrous web by molding.

Molding a fibrous web may also have the effect of decreasing the tensilestrength of the fibrous web. Generally, molding of a fibrous web isperformed in a two-dimensional pattern. By “two-dimensional pattern”herein is meant a pattern that extends in at least two directions, suchas the Machine Direction and the Cross Direction. A “two-dimensionalpattern” may consist of discrete (i.e. non-continuous) molded elementsor it may consist of continuous molded elements.

In the instance where the two-dimensional pattern comprises a continuousmolded element, e.g. a molded element that is continuous fromedge-to-edge across the length of the web and that is continuous fromedge-to-edge across the width of the web (for example in both theMachine Direction and the Cross Direction), a high basis weight of thefibrous web may be required in order to ensure strength in both theMachine Direction and the Cross Direction.

A one-dimensional pattern may utilize a fibrous web with lower basisweight, thereby reducing material costs, and providing products ofsuperior value. It has been discovered, however, that a one-dimensionalmolded element extending only in the Machine Direction results in aweakened molded fibrous structure relative to a one-dimensional moldedpattern extending only in the Cross Direction. Without being bound bytheory, it is believed that this weakening is a result of thepreferential orientation of fibers, within the web, parallel to theMachine Direction, and the concomitant reduced number of fibersextending parallel to the Cross Direction of the fibrous structure.

It is believed that a molded element results from the displacement offibers from the nonwoven fibrous structure. Such a displacement of suchfibers results in a weakening of the fibrous structure in the vicinityof the molded element, as these fibers, so displaced, are no longeravailable to bond to adjacent fibers. In the instance where the moldedelement consists of discrete molded elements, the un-molded spacesurrounding each molded element helps to retain the overall strength ofthe fibrous structure, despite the molded elements. In the instancewhere the molded element comprises a continuous molded element, thedisplacement of fibers within the fibrous structure will be continuousacross at least one dimension of the fibrous structure, and as such,maintaining the strength of the fibrous structure with a continuousmolded element is a problem. To maintain the overall strength of thefibrous structure in the instance of a continuous molded element, it isimportant to provide a sufficient number of fibers within the fibrousstructure with the capability to “span” the molded element, having aportion of the individual “spanning” fiber disposed on either side ofthe molded element. Such “spanning” fibers would, optimally, be disposedto be substantially perpendicular to the orientation of the continuousmolded element.

One approach to ensuring a sufficient number of fibers orientedsubstantially perpendicular to the continuous molded element is toincrease the total number of fibers within the fibrous structure,thereby increasing the number of fibers disposed in all orientations,thereby increasing the number of fibers that will be oriented so as tobe substantially perpendicular to the continuous molded element. Thisapproach, while effective, requires increasing the basis-weight of thefibrous structure, which requires an increased amount of material, andincreased cost.

A preferred approach to maintaining web strength in the instance of aone-dimensional continuous molded element is to orient the direction ofthe molded element to be non-parallel to the dominant fiber-orientationdirection within the web. As the Machine Direction is typically parallelto the dominant fiber orientation direction, this amounts to orientingthe direction of the continuous one-dimensional molded element to benon-parallel to the Machine Direction. It can be appreciated by one ofordinary skill in the art that the web strength will increase,accordingly, as the one-dimensional continuous molded element becomesincreasingly oriented in the Cross Direction, and decreasingly orientedin the Machine Direction.

Molding in the Cross Direction may result in higher tensile strength andmodulus of the fibrous structure. This may be demonstrated in the tablebelow in which two different molding patterns are arranged in theMachine Direction and again in the Cross Direction. Thus, Pattern #1 isoriented in the Machine Direction on a molding member. Pattern #1 isalso oriented in the Cross Direction on a separate molding member. Thesame may be done for Pattern #2. An increase in both the tensilestrength and the modulus may be demonstrated when the patterns areoriented in the Cross Direction as opposed to the Machine Direction.

TABLE 1 Pattern #1 Pattern #2 Molded Element Orientation MD CD MD CD MDTensile Strength (N) 84 96 88 97 MD Initial Slope/Modulus (N/m) 31084042 3248 3880 CD Tensile Strength (N) 20 25 20 25 CD InitialSlope/Modulus (N/m) 36 47 45 46

Tensile strength may be measured using EDANA method 20.2-89 in both thecross direction and machine direction. The Modulus may be taken as theinitial slope of the tensile curve per the same EDANE method.

The degree to which the orientation of the continuous one-dimensionalmolded element being non-parallel to the Machine Direction contributesto the strength of the resulting web also depends on the degree to whichthe fibers in the nonwoven fibrous structure are preferentially orientedin the Machine Direction. To the extent to which the fiber orientationwith the nonwoven fibrous structure is purely homogeneous, the benefitto the strength of the fibrous structure derived from orienting theone-dimensional continuous molded element to be non-parallel to theMachine Direction is lost. Said another way, in a nonwoven fibrousstructure in which the fiber orientation is purely homogeneous, thefibrous structure strength would be un-effected by the orientation ofthe continuous one-dimensional molded element. However, to the extentthat the fiber orientation is heterogeneous (typically, preferentiallyoriented to be parallel to the Machine Direction), imparting theone-dimensional molded element in an orientation that is non-parallel tothe Machine Direction becomes important.

A number of means of determining fiber orientation heterogeneity areknown. In one such typical method, a fibrous nonwoven structure isexamined under a microscope, and the number of fibers oriented atdifferent angles relative to the Cross Direction (taken as angle=0°, andthen again angle=180°) are counted via grey scale discrimination, suchas may be detected by an automated software that may identify and verifythe presence of fibers. Typically the number of fibers orientated ineach direction are grouped into “bins” of 10-degree increments, and thefinal result is reported as a per-cent of the total fibers counted whichreside in each bin.

Below is a representation of fiber orientation for a hydroentangledfibrous structure.

TABLE 2 Bin Range (degrees) Mean (% of fibers)  0-10 4.4 10-20 4.8 20-305.1 30-40 5.0 40-50 5.1 50-60 5.5 60-70 6.2 70-80 6.6 80-90 7.3  90-1007.5 100-110 6.8 110-120 6.2 120-130 5.5 130-140 4.9 140-150 4.8 150-1604.6 160-170 4.8 170-180 5.0 Total Percent 100.0

From these data, it is possible to calculate the net heterogeneity ofthe fiber orientation within the fibrous nonwoven structure.Specifically, the net fiber orientation in the Machine Direction (FOMD)would be taken as:

${FOMD} = {\sum\limits_{n = 1}^{nB}{{{Sin}\left\lbrack {\left( {n - 0.5} \right) \times B} \right\rbrack} \times \%\mspace{14mu} B_{n}}}$While the net fiber orientation in the Cross Direction (FOCD) would betaken as:

${FOCD} = {\sum\limits_{n = 1}^{nB}{{{Cos}\left\lbrack {\left( {n - 0.5} \right) \times B} \right\rbrack} \times \%\mspace{14mu} B_{n}}}$where:

-   -   nB=Number of Bins    -   B=Bin Size    -   % Bn=% of fibers in Bin number n        The net heterogeneity of fiber orientation within the fibrous        nonwoven structure would, then, be characterized as the ratio of        the FOMD to the FOCD.        Net Fiber Orientation=FOMD/FOCD        Note that a fibrous nonwoven structure with a purely homogeneous        fiber orientation would have a Net Fiber Orientation of 1,        indicating equal net fiber orientation in the Machine and Cross        Directions. A Net Fiber Orientation of greater than 1.0 would        indicate a heterogeneous fiber orientation, with a net        preferential orientation in the Machine Direction. A Net Fiber        Orientation of less than 1.0 would indicate a heterogeneous        fiber orientation, with a net preferential orientation in the        Cross Direction. It can be appreciated by one of ordinary skill        in the art that the theory regarding the need to orient the        continuous one-dimensional molded element to be non-parallel to        the Machine Direction for a fibrous web in which the Net Fiber        Orientation is greater than 1.0 would equally apply to the need        to orient the one-dimensional continuous molded element to be        non-parallel to the Cross Direction for a fibrous web in which        the Net Fiber Orientation is less than 1.0.

A web for which it is important to orient a one-dimensional moldedelement in non-parallel direction to the Machine Direction may have aNet Fiber Orientation of greater than about 1.0, more preferably greaterthan about 1.1 and even more preferably greater than about 1.3. Thehydroentangled fibrous structure represented in Table 2 above has a netfiber orientation of 1.16.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention. To the extent that any meaning ordefinition of a term in this written document conflicts with any meaningor definition of the term in a document incorporated by reference, themeaning or definition assigned to the term in this written documentshall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

The molded, textured, spunlaced, nonwoven web of the present inventionwhich can be used to make pre-moistened wipes, which can also bereferred to as “wet wipes” “wipes” and “towelettes”, are suitable foruse in cleaning babies, and can also find use in cleaning tasks relatedto persons of all ages. Such wipes can also include articles used forapplication of substances to the body, including but not limited toapplication of make-up, skin conditioners, ointments, sun-screens,insect repellents, and medications. Such wipes can also include sucharticles used for cleaning or grooming of pets, and articles used forgeneral cleansing of surfaces and objects, such as household kitchen andbathroom surfaces, eyeglasses, exercise and athletic equipment,automotive surfaces, and the like. These wipes contain the molded,textured, spunlaced, nonwoven web and a composition of matter releasablycombined therewith. The manufacture of compositions suitable forapplication via wipes are well known and form no part of this invention.Examples of compositions and/or ingredients which can be releasablycombined with the molded, textured, spunlaced, nonwoven web of thepresent invention to make wet wipes can be found in U.S. Pat. Nos.6,300,301 issued on Oct. 9, 2001, to Moore; 6,361,784 issued on Mar. 26,2002, to Brennan; 6,083,854 issued on Jul. 4, 2000, to Bogdanski;5,648,083 issued on Jul. 15, 1997, to Blieszner; 5,043,155 issued onJul. 15, 1997, to Puchalski; 6,207,596 issued on Mar. 27, 2001, toRourke; 5,888,524 issued on Mar. 30, 1999, to Cole; 5,871,763 issued onFeb. 16, 1999, to Luu; 4,741,944 issued on May 3, 1988, to Jackson;3,786,615 issued on Jan. 22, 1974, to Bauer; and 6,440,437 issued onJan. 22, 1974, to Krzysik, and various formulas.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. A molded fibrous structure having a dominant fiber orientationparallel with a Machine Direction and perpendicular to a CrossDirection, and comprising a pattern of continuous hydro-molded elementseach comprising either a raised area or lowered area, each beingoriented in a non-Machine Direction, each being continuous along saidnon-Machine Direction.
 2. The fibrous structure of claim 1 wherein atleast a portion of said pattern is oriented from about 85 degrees toabout −85 degrees from the Cross Direction.
 3. The fibrous structure ofclaim 2 wherein at least a portion of said pattern is oriented fromabout 45 degrees to about −45 degrees from the Cross Direction.
 4. Thefibrous structure of claim 1 wherein said continuous molded element isone-dimensional.
 5. The fibrous structure of claim 1 wherein saidfibrous structure comprises synthetic fibers, natural fibers, orcombinations thereof.
 6. The fibrous structure of claim 5 wherein thefibers have an average length between 1 mm and 60 mm.
 7. The fibrousstructure of claim 5 wherein the fibers have an average fiber widthgreater than 5 micrometers.
 8. The fibrous structure of claim 5 whereinthe fibers have a coarseness greater than 5 mg/100 m.
 9. The fibrousstructure of claim 5 wherein at least some of the fibers have a shapeselected from the group consisting of circular, dog bone shaped, delta,tri-lobal, and ribbon.
 10. The fibrous structure of claim 1 furthercomprising a binder.
 11. The fibrous structure of claim 10 wherein thebinder is selected from the group consisting of permanent wet strengthresins, temporary wet strength resins, dry strength resins, retentionaid resins, and combinations thereof.